Drive train for a wind turbine and series of drive trains

Abstract

The invention relates to a drive train (14) for a wind turbine (10), with a transmission (18) for transferring and converting a torque originating from a rotor shaft (16) of a rotor (12), wherein the transmission (18) has an input transmission component, more particularly a planet carrier (32), that is unsupported at least on the rotor side for introducing the torque into the transmission (18), and a coupling unit (46), designed separately from the rotor shaft (16) and from the transmission (18), for the torque-transferring coupling of the rotor shaft (16) to the input transmission component, wherein the coupling unit (46) has a bearing (48) for supporting the unsupported input transmission component within the coupling unit (46). By adapting the bearing of the input transmission component within the separately designed coupling unit (46) to different requirement profiles, a change to the structure of the transmission (18) can be avoided, therefore enabling a cost-effective drive train (14) for different wind turbines.

Description

[0001] Drive train for a wind turbine and series of drive trains

[0002] Description

[0003] The invention relates to a drive train for a wind turbine, by means of which torque can be transmitted from a rotor of the wind turbine to a generator of the wind turbine. The invention further relates to a series of such drive trains.

[0004] Wind turbines use different drivetrain concepts for different requirement profiles and different generator designs. For example, an offshore wind turbine can experience much higher wind loads than an onshore wind turbine, so the gearbox used for the respective wind turbine needs to provide more or less strong mechanical support. Furthermore, differently designed generators can have different input speeds, which leads to different requirements for the gearbox ratio. Furthermore, a more or less flexible connection of the wind turbine rotor shaft to the gearbox may be required, for example, to dampen vibrations caused by rotor blade adjustment.This means that the gearbox of a wind turbine must be individually configured for each specific application, resulting in high manufacturing costs due to the associated structural modifications to the gearbox. EP 3 767 102 A1 discloses connecting a gearbox of a wind turbine to a rotor shaft of a wind turbine rotor via a torsionally rigid coupling, transmitting torque.

[0005] From WO 2007 / 085644 A1 and EP 3 232 055 A1 it is known to provide a rotor shaft bearing of a rotor shaft of a rotor of a wind turbine within a gearbox housing of a gearbox of the wind turbine.

[0006] From US 2020 / 0291927 A1 it is known to couple a rotor shaft of a wind rotor of a wind turbine, which is mounted in a main bearing of a rotor bearing arrangement, to an output shaft via an elastic coupling designed in the form of a curved toothing or an elastic element, so that an offset and tilting of the output shaft relative to the rotor shaft and its rotor bearing arrangement can be permitted.

[0007] From US 2011 / 0143880 A1 it is known to allow a rotor shaft of a wind rotor of a wind turbine, which is mounted in a main bearing of a rotor bearing arrangement, to protrude into the interior of the gearbox via a bearing provided on a gearbox housing of a gearbox or to fasten the rotor shaft, which is only mounted in the rotor bearing arrangement, to a rotatable ring gear of a planetary gear via a mounted slip clutch in order to limit the torque to be transmitted.

[0008] From US 2013 / 0300125 A1, a rotor shaft of a wind rotor of a wind turbine, which is mounted in a main bearing of a rotor bearing arrangement, is coupled via a curved tooth coupling to a planet carrier provided entirely in a gearbox housing of a gearbox, wherein the planet carrier is mounted on the rotor side within the gearbox housing.

[0009] From WO 2007 / 085644 A1 it is known to couple a rotor shaft of a wind rotor of a wind turbine, which is mounted in a main bearing of a rotor bearing arrangement, via a curved tooth coupling flanged to the rotor shaft to a planet carrier provided entirely in a gearbox housing of a gearbox supported by a torque arm.

[0010] The object of the invention is to demonstrate measures that enable a cost-effective drive train for a wind turbine.

[0011] The problem is solved by a drive train having the features of claim 1, a series having the features of claim 12, a series having the features of claim 14, and a data agglomerate having the features of claim 15. Preferred embodiments are specified in the subclaims and the following description, each of which, individually or in combination, can represent an aspect of the invention. If a feature is presented in combination with another feature, this merely serves to simplify the presentation of the invention and is in no way intended to imply that this feature cannot also be a further development of the invention without the other feature.

[0012] One aspect of the invention relates to a drive train for a wind turbine, comprising a gearbox for transmitting and converting a torque originating from a rotor shaft of a rotor mounted in a rotor bearing arrangement, wherein the gearbox has an input gearbox component, in particular a planetary carrier, which is unsupported at least on the rotor side for introducing the torque into the gearbox, wherein the input gearbox component partially protrudes from a gearbox housing and / or a ring gear of the gearbox on the rotor side, and a coupling unit designed separately from the rotor shaft, the rotor bearing arrangement and the gearbox for allowing a torque-transmitting and torsionally rigid, in particular form-fitting, coupling of the rotor shaft to the input gearbox component within the coupling unit, wherein the coupling unit has a bearing for supporting the unsupported input gearbox component within the coupling unit,wherein the input gear component on the rotor side is supported exclusively by the bearing within the coupling unit. The input-side, in particular only, bearing of the input gear component of the transmission does not take place within the transmission, but outside the transmission. The rotor-side bearing of the unsupported input gear component does not take place within the transmission, but exclusively outside the transmission in the separately designed coupling unit. In particular, the input-side bearing of the input gear component is axially spaced from a gear housing of the transmission. However, the input-side bearing of the input gear component is also not on a rotor bearing housing of the rotor bearing arrangement or on the rotor shaft, but exclusively within the coupling unit with the aid of the at least one bearing provided in the coupling unit. The coupling unit is connected to the rotor shaft,A rotor bearing housing of the rotor bearing assembly supporting the rotor shaft and the gearbox are designed separately, and can represent a structural unit designed separately from the rotor shaft, the rotor bearing housing, and the gearbox. The input gearbox component, in particular the planetary carrier, is unsupported at least on the rotor side and is only supported on the rotor side with the help of the coupling unit designed separately from the gearbox. The input gearbox component is supported on the rotor side exclusively within the coupling unit. This means that adaptation of the gearbox to different requirement profiles does not necessarily have to be carried out within the gearbox; instead, only the coupling unit is adapted accordingly.

[0013] Depending on the requirements to be met, it can be considered that the bearing of the input gear component within the coupling unit can be changed to a different bearing diameter, in particular a different shaft and / or connection diameter, and / or that any necessary spring and / or damping elements can be provided at suitable locations in the torque flow between the rotor shaft and the input gear component. The coupling unit can be configured to provide a damping and / or coupling technology according to the requirements to be met, as well as a suitable bearing for the input gear component depending on the expected mechanical loads.The coupling unit can thus act as a low-pass filter for static and / or dynamic loads and / or as an abutment for supporting wind-induced bending and / or pivoting and / or tilting moments, so that the torque flow downstream of the input transmission component results in essentially comparable, in particular almost identical, operating conditions and loads despite different requirement profiles. Since the adaptation of the drive train to the required requirement profile can essentially be provided exclusively by the coupling unit, eliminating the need for individual adjustments within the transmission, it is possible to reuse a previously developed transmission design. This can significantly reduce development costs and development times.By adapting the bearing of the input gearbox component within the separately designed coupling unit to different requirement profiles, a change in the gearbox design can be avoided, thus enabling a cost-effective drive train for different wind turbines.

[0014] The respective requirement profiles may differ, in particular, in that, at least to a limited extent, different torques and / or different bending and / or pivoting moments (tilt and yaw moments), and / or different structural rigidities and / or different rotational speeds and / or different axial vibrations and / or different radial vibrations and / or different static and / or dynamic forces in the axial direction and / or in the radial direction and / or different lubrication requirements may occur. Two requirement profiles to be compared may differ in just one requirement or in two, three, or more requirements.The different requirement profiles arise in particular from different locations of a wind turbine with different expected weather conditions and / or different rotor blade diameters and / or different rotor blade weights and / or different aerodynamic rotor blade profiles and / or different control algorithms for operating the wind turbine and / or different generators provided for power generation and / or the type and manner of rotor blade adjustment.

[0015] The input transmission component is a functional component of the transmission which, in interaction with at least one other transmission component, can effect a speed ratio that is permanently different from i = 1.0 under constant operating conditions. A component of a constant-speed coupling, for example spline gearing, short gearing and / or curved gearing, or a component of an elastic coupling which only permits a limited speed variance around a mean value with a ratio i = 1.0 under constant operating conditions, is not considered a transmission component due to the lack of an achievable speed conversion. The input transmission component can, for example, have gearing embedded in the transmission, which can be part of a spur gearing or part of a planetary gear.Preferably, the input gear component is designed as a planet carrier of a planetary gear, on which planetary gears are rotatably mounted, radially spaced from a main rotational axis, so that the rotational speed of the input gear component can be converted by the planetary gears meshing with a sun gear and / or a ring gear. Preferably, the ring gear is immobile, so that the gear configured as a planetary gear achieves a high-speed transmission. Preferably, the gear has more than one gear stage, with the input-side input gear component being part of the first gear stage in the direction of torque flow.

[0016] The bearing of the coupling unit is particularly designed to mount that part of the input transmission component which is inserted into the coupling unit, so as to be relatively rotatable relative to a preferably stationary coupling housing. In particular, the bearing is arranged at least partially in a common axial region with the input transmission component. Preferably, the bearing is provided entirely within the coupling housing of the coupling unit, in particular is fastened to the coupling housing in a rotationally fixed manner. The bearing, together with the coupling housing as a common structural unit, can completely or partially form the coupling unit which is designed separately from the transmission and separately from the rotor. The coupling unit is positioned in particular in the axial direction between a transmission housing of the transmission and a rotor bearing housing of the rotor bearing arrangement provided for supporting the rotor shaft.The rotor shaft protruding from the rotor bearing housing of the rotor bearing arrangement and / or the input gear component protruding from the gearbox housing can be partially inserted, i.e. introduced, into the coupling unit, in particular into the coupling housing. The bearing can be designed in particular to support tilting moments introduced via the rotor shaft and / or the input gear component. For this purpose, the bearing can be designed in particular to transfer significant axial loads. This makes it possible, in particular, for the gearbox to be designed for only a specific torque to be transmitted for different drive train concepts and different rotor shaft bearing arrangements, without the need to compensate for different axial loads depending on the application. Compensation for different axial loads can be achieved by suitable adaptation of the bearing in the coupling unit.

[0017] The rotor bearing assembly is located upstream of the gearbox and coupling unit in the direction of torque. The rotor bearing assembly has a stationary rotor bearing housing in which at least one rotor bearing, also referred to as the "main bearing," is provided, with the aid of which the rotor shaft coupled to the (wind) rotor can be mounted. In particular, at least two rotor bearings spaced apart from one another in the axial direction are provided. As a rule, the at least two rotor bearings are significantly spaced apart from one another in the axial direction in order to be able to support the very considerable loads of the rotor. The rotor bearings and the rotor bearing housing of the rotor bearing assembly are designed to support the dead weight of the rotor and the rotor shaft as well as the wind loads acting on the rotor during operation of the wind turbine. The rotor bearing assembly is a separate structural unit from the gearbox and coupling unit.The coupling unit is a separate structural unit distinct from the gearbox and the rotor bearing assembly. The rotor shaft can protrude from the rotor housing of the rotor bearing assembly on an axial side facing away from the rotor. The part protruding from the rotor housing of the rotor bearing assembly can be coupled directly or indirectly to the input gearbox component, in particular the hub of a planetary carrier. For this purpose, the rotor shaft can preferably partially penetrate the coupling unit and be coupled within the coupling unit in a torque-transmitting and torsionally rigid manner, in particular rigidly and / or positively.

[0018] The coupling unit can permit the torque-transmitting coupling of the rotor shaft, which is supported by the rotor bearing arrangement, with the input gear component within the coupling unit insofar as the coupling unit provides sufficient installation space for the coupling of the rotor shaft with the input gear component and additionally provides accessibility for a tool in order to use the tool to create the coupling, for example a flange screw connection. In this case, it is possible for the input gear component to already be mounted in the bearing of the coupling unit when the torque-transmitting coupling with the rotor shaft has been created, which simplifies assembly. However, it is also possible for the input gear component to be moved, in particular drawn, into the bearing only by the forces applied with the aid of the tool to create the torque-transmitting coupling.This makes it easier to create a press fit within the coupling unit between the previously unsupported input gear component on the rotor side (i.e., on the input side) and the coupling unit bearing, and to press the input gear component into the coupling unit bearing. The coupling unit bearing can thus be pre-assembled in the coupling unit for the torque-transmitting coupling of the rotor shaft with the input gear component, achieving a low-wear bearing for the input gear component.Instead of directly connecting the gearbox and the rotor bearing assembly, which would require the complete mounting of both the output side of the rotor bearing assembly and the input side of the gearbox, an indirect connection of the gearbox to the rotor bearing assembly can be achieved using a coupling unit designed separately from the rotor bearing assembly and the gearbox. The coupling unit, together with the bearing for the input gearbox component, can be cost-effectively replaced to adapt the gearbox to a different requirement profile. The coupling unit is shorter, in particular, in the axial direction than in the radial direction. The coupling unit can preferably be mounted on the input gearbox component and / or the rotor shaft.The coupling unit not only serves to couple the rotor shaft to the input gear component, but also to support the input gear component and / or act as an axially acting abutment to support the rotor shaft against wind loads. Preferably, the coupling unit provides the sole support for the input gear component, obviating the need for a direct support for the input gear component within the gearbox. If necessary, the input gear component is retained captively within the gearbox by the gearbox housing. Preferably, the rotor shaft can partially extend into the coupling unit and be coupled to the input gear component within the coupling unit in a torque-transmitting and torsionally rigid manner, in particular rigidly and / or positively.In particular, the coupling between the rotor shaft and the input gear element is designed to transmit unlimited torque and is essentially speed-stable. The coupling is particularly designed to be positively engaged, preventing frictional engagement between the rotor shaft and the input gear element that can be overcome under load.

[0019] The wind turbine has, in particular, a tower connected to a subsurface on which a nacelle is provided. The drive train can be provided in the nacelle. The drive train can be attached to the nacelle via a machine frame, which can serve as a foundation. The rotor shaft connected to the coupling unit can protrude from the nacelle and be connected to rotor blades outside the nacelle via a rotor hub in order to form the (wind) rotor of the wind turbine. The angle of attack of the rotor blades can be changed, in particular with the aid of a rotor blade control, in particular in order to adjust the loads introduced via the rotor depending on the current weather conditions and / or to avoid overloads. The input gear component can protrude from the gear unit, in particular a gear housing, on the input side, i.e. directed towards the rotor, and can thus be easily coupled to the coupling unit.

[0020] The transmission can have an output transmission component, in particular a sun gear shaft, which on the output side, directed away from the rotor, points towards a generator. The output transmission component can protrude from the transmission, in particular the transmission housing, and protrude into a generator housing of the generator, where the output transmission component of the transmission can be connected to a generator shaft of a rotor of an electric machine of the generator. Alternatively, the generator shaft of the generator can protrude into the transmission and be connected, in particular within the transmission housing, to the output transmission component. The generator can generate electrical energy from the introduced torque, which can in particular be fed to a power grid.

[0021] In particular, it is provided that the transmission has at least one planetary stage with a planetary gear, and the input transmission component is a planetary carrier of the planetary gear facing the rotor shaft, wherein the planetary carrier has an unsupported planetary carrier hub protruding towards the rotor shaft, wherein the planetary carrier hub is supported in the coupling unit. The planetary carrier hub protruding from a planetary carrier web can be easily inserted into the coupling unit and supported directly or indirectly within the coupling unit. The planetary carrier hub can also protrude slightly from a transmission housing of the transmission, so that no significant adaptations to the transmission are required to couple the coupling unit to the input transmission component.The torque coming from the rotor can be introduced into the respective planetary stages via the planet carrier and output via a sun gear shaft, so that each planetary stage can provide a high gear ratio. The planet carrier hub is in particular designed as a single piece with at least one planet carrier cheek of the planet carrier. The planet carrier can be at least roughly centered and roughly fixed in its relative position in the planetary gear system of the planetary stage by the at least one planet gear meshing with the sun gear and the ring gear, wherein it is possible to temporarily fix the planet carrier with the aid of at least one fixing element for transport and assembly. The bearing in the coupling unit with the aid of the bearing of the coupling unit is sufficient to mount the planet carrier and to fix its relative position within the planetary stage in a defined manner.The bearing in the coupling unit can be designed such that wind-induced deformations and displacements between a rotor shaft connection in the coupling unit and a ring gear of the gearbox can be kept preferably smaller than or equal to the permissible displacements in the pre-developed main gearbox, which is to be used as a gearbox for various drive trains. This behavior can be advantageously optimized through the selected structural rigidity of the coupling unit as well as the bearing preload and / or bearing clearance in the coupling unit.

[0022] The transmission can have exactly one gear stage, in particular designed as a planetary stage, wherein the transmission can preferably have two, three, four or more gear stages. Each gear stage has the planetary gear, which can have as transmission components a sun gear, at least one planet gear meshing with the sun gear, a ring gear meshing with the planet gear, and a planet carrier rotatably supporting the planet gear. The sun gear and a sun gear shaft connected to the sun gear, the planet carrier, and the ring gear are arranged substantially coaxially to one another, wherein the ring gear is preferably held in a rotationally fixed manner, in particular is fastened to the immovable transmission housing in a movement-proof manner, while the sun gear and the planet carrier are rotatably supported, in particular on the transmission housing and / or on one another.The at least one planetary gear can be rotatably mounted on the planetary carrier at a predetermined radius relative to the transmission's axis of rotation, which coincides with the axis of rotation of the sun gear and / or the planetary carrier. For this purpose, the at least one planetary gear can be mounted on a planetary axle rigidly attached to the planetary carrier, or the respective planetary gear has a planetary gear shaft rigidly attached to the planetary gear and mounted in at least one planetary gear cheek of the planetary carrier, preferably in a respective planetary gear cheek at both axial ends. Preferably, three, five, or seven planetary gears are provided, which are distributed evenly in the circumferential direction.

[0023] Preferably, the bearing bears directly against the input transmission component or the coupling unit has a transition piece firmly connected to the input transmission component for providing a bearing surface on a bearing diameter different from the input transmission component, wherein the bearing bears directly against the bearing surface of the transition piece. If the bearing of the coupling unit bears directly against the input transmission component, the input transmission component itself can form a bearing surface to which, for example, a bearing ring of the bearing can be fastened. If the input transmission component is only indirectly supported by the bearing of the coupling unit with the aid of the transition piece, the transition piece can be fastened to the input transmission component and it is the transition piece that forms the bearing surface for the bearing.The bearing surface of the transition piece is provided on a bearing diameter that differs from the outer and / or inner diameter of the part of the input transmission component that protrudes into the coupling unit. With the help of the transition piece, the input transmission component can thus be mounted on a bearing diameter that is not provided at all in the input transmission component without the transition piece. The bearing of the input transmission component can thus be easily adapted to a requirement profile that, due to the loads encountered and / or space restrictions, requires a bearing diameter that is not provided by the input transmission component alone. An adaptation of the input transmission component itself is not necessary. Depending on the requirement profile, a differently dimensioned transition piece can be installed in the coupling unit.

[0024] The bearing is particularly preferably designed as a plain bearing or rolling bearing, in particular a tapered roller bearing. Depending on the requirements profile, a plain bearing or a rolling bearing may be more suitable. Depending on the requirements profile, the bearing is designed to absorb only radial forces, only axial forces, or both axial and radial forces, or deliberately not to support them. The bearing can in particular be composed of several partial bearings, for example an axial bearing, in particular an axial plain bearing, and a radial bearing, in particular a radial plain bearing, or two tapered roller bearings in an X-arrangement or O-arrangement. Installation space restrictions for a specific desired bearing arrangement can be counteracted, for example with the help of the transition piece, even if the dimensions of the input gearbox component are unfavorable for the desired bearing arrangement.

[0025] In particular, the coupling unit has at least one support foot for transferring mechanical loads to a stationary component, in particular a rotor bearing housing of the rotor bearing arrangement provided for supporting the rotor shaft and / or for transferring mechanical loads to a gearbox housing and / or ring gear of the gearbox and / or for transferring mechanical loads to a foundation for supporting the drive train. The support foot can in particular be fixedly attached to the stationary component in a movement-resistant manner or can be pressed against the stationary component due to the forces to be transferred. Mechanical loads can thus be at least partially diverted and transferred past the input gearbox component, so that the gearbox is not overloaded even under demanding requirements. The support foot is intended in particular for transferring forces in the axial direction and / or in the radial direction.

[0026] The coupling unit preferably has a torque arm for supporting the torque coming from the rotor shaft against a / the stationary component(s), in particular a rotor bearing housing of the rotor bearing arrangement provided for supporting the rotor shaft and / or for transferring mechanical loads to a gearbox housing and / or ring gear of the gearbox and / or for transferring mechanical loads to a foundation for supporting the drive train. The torque arm is provided in particular for transferring forces in the circumferential direction. Because the torque arm of the coupling unit is provided outside the gearbox, torque support does not need to be provided in the gearbox. Depending on the requirements profile, the torque arm of the coupling unit can be dimensioned for larger or smaller loads without any adjustments to the gearbox being necessary.

[0027] The coupling unit particularly preferably has an axial spring element and / or an axial damper element for the flexible support of axial forces, in particular those caused by the dead weight of the gearbox. A weight of the gearbox can impose a tilting moment from a radial plane of the gearbox. This tilting moment can be supported by the axial spring element and / or an axial damper element of the coupling unit and tilting from the radial plane can be prevented or limited to a tolerable extent. Depending on the installation situation of the gearbox in the drive train and the intended requirement profile, a different tilting moment can occur. This can be absorbed by adapted dimensioning of the axial spring element and / or the axial damper element without any adjustments within the gearbox being necessary.

[0028] In particular, the coupling unit comprises an elastic coupling connectable to the rotor shaft, wherein the elastic coupling is designed to be torsionally rigid and flexible in the axial and / or radial directions. The elastic coupling can transmit the introduced torque with virtually no loss, while axial and / or radial shocks can be damped and / or absorbed. For example, the elastic coupling comprises laminated cores and / or plates that can be resilient in the axial and / or radial directions, but can transmit torque in a torsionally rigid manner in the circumferential direction. Preferably, the coupling unit comprises a through-opening, in particular a central one, for passing a pitch tube between the rotor shaft and the gearbox.Control lines, particularly electrical and / or hydraulic ones, for operating a rotor blade pitch control system can be routed through the pitch tube through the gearbox, the coupling unit, and the rotor shaft, allowing the angle of attack of rotor blades connected to a rotor hub of the rotor shaft to be adjusted. The operation of a rotor blade pitch control system is not significantly impaired by the coupling unit.

[0029] The coupling unit particularly preferably has a lubricant channel for exchanging a lubricant, in particular lubricating oil, between the rotor shaft and the input gearbox component. The lubricant can preferably also be used to lubricate the bearing of the coupling unit and can be branched off from the lubricant channel via a lubrication channel provided for this purpose. The lubricant channel of the coupling unit can also enable a common lubricant supply for the rotor and the gearbox through the coupling unit. In particular, it is possible to adapt a lubricating oil flow to different requirement profiles by dimensioning the flow cross-section of the lubricant channel in the coupling unit, without having to make changes to the lubrication concept within the gearbox. A throttling effect of the lubricant channel in the coupling unit can be adjusted to be greater or lesser for this purpose.

[0030] In particular, the coupling unit has at least one rotor fastening means accessible radially outside the coupling unit for releasably fastening the coupling unit to the rotor shaft and / or at least one gear fastening means accessible radially outside the coupling unit for releasably fastening the coupling unit to the input gear component of the transmission. The coupling unit can be pre-assembled with the transmission and easily fastened to the rotor shaft using the rotor fastening means. It is also possible for the coupling unit to be pre-assembled with the rotor shaft and easily fastened to the input gear component using the gear fastening means.Preferably, the coupling element for coupling the gearbox to the rotor does not need to be pre-assembled to the rotor shaft or the input gearbox component, but can be fastened to the rotor shaft and the input gearbox component using the easily accessible rotor fastening means and gearbox fastening means after the gearbox has already been positioned relative to the rotor. In particular, the gearbox is guided on a machine carrier so that it can be moved relatively axially relative to the rotor shaft, so that the input gearbox component can be easily inserted into the coupling unit, which may already be fastened to the rotor shaft, for example. A fitter can easily monitor the threading of the input gearbox component into the coupling unit and intervene if necessary.When the input gear component is inserted into the coupling unit in the desired end position, the relative position of the gear to the rotor can be determined, preferably with the aid of the gear fastening means.

[0031] One aspect of the invention relates to a series of drive trains, comprising a first drive train designed for a first requirement profile, which can be designed and further developed as described above, and a second drive train designed for a second requirement profile, which can be designed and further developed as described above, wherein the transmission of the first drive train and the transmission of the second drive train are designed essentially identically and the coupling unit of the first drive train is designed differently from the coupling unit of the second drive train. The series can in particular be designed and further developed as described above.By adapting the bearings of the input gear component within the separately designed coupling unit to different requirement profiles, a change in the design of the gearbox can be avoided, thus enabling a cost-effective drive train for different wind turbines. Preferably, the first drive train is connected to a first generator and the second drive train to a second generator, with the first generator and the second generator being designed for different power profiles. This takes advantage of the fact that the gearbox can meet very different output-side power profiles over a certain operating range. This makes it possible to adapt the drive train to the output-side power profile of the generator on the input side in the coupling unit.For example, a generator designed for a higher rated speed may require more cooling in the gearbox than one designed for a lower rated speed. This can be accommodated by a lower throttling effect when passing cooling oil from the rotor shaft through the coupling unit into the gearbox. Different loads, in particular tilting moments, which can result from whether or not the generator is supported on a foundation or machine frame in the generator area, can be compensated for by dimensioning the coupling unit without requiring any adjustments to the gearbox. In addition, a change in the generator's power profile, for example in the event of a grid-side fault, can be absorbed by the coupling unit without requiring any adjustments to the gearbox.If the originally planned gearbox ratio no longer fits when replacing the generator, it is possible to install an intermediate stage, such as a planetary or spur gear stage, between the gearbox and the generator, especially one that can be mounted separately, without having to modify the rest of the gearbox. The gearbox ratio can be selected to be cost-optimized for the rated generator torque and the generator's operating speed. This optimization can take into account typical wind rotor speeds depending on the rotor diameter, wind classes, turbine power, and maximum blade tip speeds, as well as typical maximum switching frequencies of electrical components, to achieve the optimal cost.A drive train of this series can easily be used for different drive train concepts and different requirement profiles without adapting the gear generator combination, for example for onshore and / or offshore with the associated better separability into transport modules and reduced logistics costs or sound-critical locations with or without a decoupling element.

[0032] A further aspect of the invention relates to a series of drive trains, with a first generator designed for a first power profile and a first drive train connected to the first generator, which can be designed and further developed as described above, as well as a second generator designed for a second power profile and a second drive train connected to the second generator, which can be designed and further developed as described above, wherein the transmission of the first drive train and the transmission of the second drive train are essentially identical and the coupling unit of the first drive train is designed differently from the coupling unit of the second drive train. The series can be designed and further developed in particular as described above with reference to the drive train and / or with reference to the series.This takes advantage of the fact that the transmission can accommodate a wide range of output power profiles over a certain operating range. This allows the drive train to be adapted to the generator's output power profile on the input side in the coupling unit.

[0033] Different loads, in particular tilting moments, which can arise depending on whether the generator is supported on a foundation or machine frame in the generator area or not, can be compensated for by dimensioning the coupling unit without requiring any adjustments to the gearbox. In addition, a change in the generator's power profile, for example in the event of a grid-side fault, can be absorbed by the coupling unit without requiring any adjustments to the gearbox. If the originally intended gear ratio of the gearbox is no longer suitable when the generator is replaced, it is possible to provide an intermediate stage, for example a planetary stage or spur gear stage, which can be mounted separately, between the gearbox and the generator without having to modify the rest of the gearbox.The gear ratio can be selected to optimize the cost of the generator's rated torque and operating speed. This optimization can take into account typical wind rotor speeds depending on the rotor diameter, wind class, turbine power, and maximum blade tip speeds, as well as typical maximum switching frequencies of electrical components, to achieve optimal costs. A drive train from this series can be easily used for different drive train concepts and various requirement profiles without adapting the geared generator combination, for example, for onshore and / or offshore applications, with the associated improved separability into transport modules and reduced logistics costs, or for sound-critical locations with or without a decoupling element.

[0034] By adapting the bearing of the input gearbox component within the separately designed coupling unit to different input-side requirement profiles and / or output-side performance profiles, a change in the gearbox design can be avoided, thus enabling a cost-effective drive train for different wind turbines.

[0035] One aspect further relates to a data agglomerate with data packets summarized in a common file or distributed across different files for mapping the three-dimensional shape and / or the interactions of all components provided in the drive train, which can be designed and developed as described above, wherein the data packets are prepared to carry out an additive production of the components of the drive train, in particular by 3D printing, when processed by a data processing device for operating a machine tool for the additive manufacture of devices and / or to carry out a simulation of the functioning of the drive train when processed by a data processing device for carrying out a technical simulation and to output the simulation results generated thereby for further use,in particular for the purpose of providing proof of fatigue strength as a function of variable loads and / or variable temperature loads and, if necessary, comparing it with measurement data determined on a real-life device according to the invention and / or on a prototype of the device according to the invention. The data packets of the data agglomerate are specifically adapted to the inventive design of the respective device according to the invention described above in order to be able to adequately represent the inventive interaction of the components of the device according to the invention during processing in the data processing device. The data packets can, in particular, be stored spatially distributed, but adapted to one another in such a way that, in the event that all data packets are combined in a common data processing device,the data agglomerate thus assembled provides all the necessary data for additive manufacturing and / or technical simulation with the aid of the data processing device for the device according to the invention.

[0036] For example, the data packets are each separate parts of a data library (“library”), which are combined to form the data agglomerate and are adapted to one another with regard to their relative dimensions to one another and / or absolute dimensions and / or material properties corresponding to the respective device according to the invention. The data agglomerate can represent a virtual embodiment of the respective device according to the invention in the manner of a so-called “digital twin,” which enables a virtual investigation in the form of a simulation or a real objectification using an additive manufacturing process. Such a digital twin is described, for example, in US 2017 / 286572 A1, the disclosure of which is hereby incorporated by reference as part of the invention.

[0037] When the data processing device of the machine tool processes the data agglomerate, the device according to the invention is produced, so that after processing the data agglomerate in the data processing device, the device according to the invention is obtained, at least in the form of a prototype. In particular, each data packet can represent a separately implemented component of the respective associated device according to the invention, so that the individual components can easily be assembled, actually and / or virtually, in terms of their relative position and / or relative mobility in order to realize the interactions essential to the invention. In particular, it is possible, with the aid of the respective data packets, to produce the various components of the respective device separately and, if appropriate, from different materials by additive manufacturing and subsequently assemble them to form a prototype of the respective device.The division of the data of the data agglomerate into different data packets thus enables a simple sequential additive production of components of the respective device that are movable relative to one another in the form of a kit (“kit of parts”), which is designed to only be assembled in a meaningful way for the inventive interaction of the components of the prototype for the solution of the problem underlying the invention.

[0038] Additionally or alternatively, it is possible to use the data packets of the data agglomerate in a virtual environment during a technical simulation to calculate and / or predict the individual components of the respective device, their interactions, the physical state, and / or the change in physical parameters as a function of various boundary conditions and / or over time of the associated device according to the invention, and to further use them to check whether the device according to the invention is sufficiently suitable for the intended purpose based on the assumed design and taking into account the assumed simulated influences. If the data agglomerate is processed by a data processing device that maps the simulation environment, it is possible to examine the behavior of the device according to the invention taking into account boundary conditions, in particular changing ones.This makes it possible, for example, to investigate centrifugal force effects on individual components of the device according to the invention as a function of various static and / or dynamic loads and / or different operating temperatures, whereby such simulation results can be incorporated into the preparation of a fatigue strength verification. Preferably, the simulation results obtained after processing the data agglomerate in the data processing device for the simulation environment are stored in order to compare them with measurement data determined on an actually produced device according to the invention and / or on a prototype of the device according to the invention. This makes it possible to assess the quality of the simulation results obtained with the aid of the data agglomerate and / or, in particular in the case of particularly significant deviations, to identify measurement errors and / or an erroneous measurement.Non-destructive quality control of the device according to the invention is thereby simplified and improved.

[0039] The data agglomerate enables the cost-effective production of prototypes and / or computer-based simulations to study the functionality of the rotating body and / or the holding tool, identify problems in the specific application, and find improvements. The solution to the problem underlying the invention can be easily and cost-effectively verified using the data agglomerate.

[0040] The invention will be explained below by way of example with reference to the accompanying drawings using preferred embodiments, wherein the features presented below can represent an aspect of the invention both individually and in combination. They show:

[0041] Fig. 1 : a schematic perspective view of a wind turbine,

[0042] Fig. 2: a schematic side view of part of a drive train of the wind turbine from Fig. 1,

[0043] Fig. 3: a schematic sectional view of a first embodiment of a coupling unit for the drive train from Fig. 2,

[0044] Fig. 4: a schematic sectional view of a second embodiment of a coupling unit for the drive train from Fig. 2,

[0045] Fig. 5: a schematic sectional view of a third embodiment of a coupling unit for the drive train from Fig. 2,

[0046] Fig. 6: a schematic sectional view of a fourth embodiment of a coupling unit for the drive train from Fig. 2, Fig. 7: a schematic basic representation of a fifth embodiment of a coupling unit for the drive train from Fig. 2 in the installed state and Fig. 8: a schematic basic representation of the coupling unit from Fig. 6 for the drive train from Fig. 2 in the installed state.

[0047] The wind turbine 10 shown in Fig. 1 can be used to generate electrical energy from wind power. For this purpose, the wind turbine 10 has a rotor 12 that can be rotated by wind power. The rotor 12 is coupled to a drive train 14. For this purpose, the rotor 12 is connected to a rotor shaft 16, which is coupled within the drive train 14 to a gearbox 18 in order to convert the torque introduced via the rotor 12 and the rotor shaft 16. The torque converted in the gearbox 18 is fed to an electrical machine operated in generator mode, which represents a generator 20. The electrical energy generated by the generator 20 can be fed to a rechargeable battery and / or a power grid. In the illustrated embodiment, the drive train 14 is entirely housed in a nacelle 22, which is attached to an upper free end of a tower 24.

[0048] As shown in Fig. 2, the transmission 18 of the drive train 14 coupled to the generator 20 can have a plurality of planetary stages 28 housed in a transmission housing 26, of which the input-side planetary stage 28 is shown without a transmission housing 26. The respective planetary stage 28 is designed as a planetary gear in which an input-side torque can be introduced via a planet carrier hub 30 of a planet carrier 32 and output via a sun gear shaft 36 connected to a sun gear 34. The sun gear shaft 36 of the input-side planetary stage 28 and the planet carrier hub 30 of the subsequent planetary stage 28 can be connected to one another, in particular can be formed into one piece. At least one planetary gear 40 is rotatably mounted on the planetary carrier 32, in particular a two-cheek one, radially spaced from a rotational axis 38, which planetary gear meshes both with the sun gear 34 and with a ring gear 42 fastened to the gear housing 26 in a rotationally fixed manner.Here, the radially outward-facing outer side of the ring gear 42 can form a part of the transmission housing 26 that is not separately covered radially outward by the rest of the transmission housing 26. The planet gear 40 is rotatably mounted on the planet carrier 32 via a planet pin 44, wherein the planet pin can be designed as a planet gear axle that is non-rotatably attached to the planet carrier 32 and mounted for relative rotation in the planet gear 40, or as a planet gear shaft that is non-rotatably attached to the planet gear 40 and mounted for relative rotation in the planet carrier cheeks of the planet carrier 32. The planet carrier hub 30, the planet carrier 32, the sun gear 34, and the sun gear shaft 36 of the respective planetary stage 28 are hollow, in particular as a hollow shaft, so that a pitch tube can be guided through the transmission 18 to the rotor shaft 16 of the rotor 12.

[0049] The planet carrier hub 30 can, for example, be inserted and / or flanged into the coupling unit 46 shown in Fig. 3, wherein, for the sake of simplicity, only the planet carrier hub 30 of the planet carrier 32 of the input-side planetary stage 28 of the transmission 18 is shown. The coupling unit 46 has a bearing 48, via which the planet carrier hub 30 and thus the planet carrier 32 are mounted in the coupling unit 46. The bearing 48 replaces an otherwise required input-side bearing of the planet carrier 32 within the transmission 18, which is thus eliminated. The planet carrier 32 of the transmission 18 is unsupported at least on the rotor side and is only supported on the rotor side with the aid of the coupling unit 46, which is designed separately from the transmission 18. The rotor-side bearing of the planet carrier 32 takes place exclusively within the coupling unit 46.In the illustrated embodiment, the bearing 48 is designed as a double-row tapered roller bearing in an O-arrangement. Such a bearing 48 can completely support the planet carrier 32, so that no further bearing is required to support the planet carrier 32, and the bearing 48 of the coupling unit 46 can be the only bearing for supporting the planet carrier 32. The coupling unit 46 has a coupling housing 50 which is mounted on the planet carrier hub 30 of the planet carrier 30 via the bearing 48 and which can be fixedly attached to the transmission housing 26 and / or the ring gear 42 of the transmission 18. Additionally or alternatively, it is possible to connect the coupling housing 50 to a rotor bearing housing 52 for supporting the rotor shaft 16, in particular with limited flexibility via a spring and / or damper element.The rotor shaft 16 can be attached to the planetary gear hub 30 indirectly, for example via an intermediate shaft in the coupling unit 46, or directly, for example via a flange connection. In the exemplary embodiment shown in Fig. 2, the coupling housing 50 has radially projecting torque supports 54, with the aid of which the torque to be transmitted can be suitably supported. If the requirements profile for the drive train 14, for example, provides for a 3-point bearing or a 4-point bearing of the rotor shaft 16, reaction moments as well as bending and / or pivoting and / or tipping loads and / or higher torques can be supported on the coupling housing 50 and the torque supports 54 without loading the transmission 18. To adapt to such requirements profiles, the torque supports 54 of the coupling unit 46 can be adapted in terms of their length and / or material thickness.An adjustment within the transmission 18 in order to be able to suitably support the torque to be transmitted is not necessary and can instead be carried out exclusively with the aid of the correspondingly adapted coupling unit 46.

[0050] In the embodiment of the coupling unit 46 shown in Fig. 4, in comparison to the embodiment of the coupling unit 46 shown in Fig. 3, an elastic coupling 56 can be provided in addition to or as an alternative to the torque arm 54. In the illustrated embodiment, this coupling is torsionally rigid, but can be elastically flexible in the axial and / or radial directions. This enables flexible and / or elastic decoupling. If the requirement profile for the drive train 14 provides for shocks introduced via the rotor shaft 16 in the axial and / or radial direction, these shocks can be dampened and / or absorbed by the elastic coupling 56 within the coupling unit 46 without any adjustments having to be made to the transmission 18.

[0051] In the embodiment of the coupling unit 46 shown in Fig. 5, in comparison to the embodiment of the coupling unit 46 shown in Fig. 4, the elastic coupling 56 can be provided between the rotor bearing housing 52 and the coupling housing 50. For this purpose, the elastic coupling 56 can be designed to be flexible in the circumferential direction, but in particular can be rigidly coupled to the rotor bearing housing 52 and the coupling housing 50 in the axial and / or radial direction. If the requirements profile for the drive train 14 includes sound-sensitive wind turbine locations, excitation frequencies originating from the generator 20 and / or the gearbox 18 can be decoupled from the rotor shaft 16, whereby noise emissions can be avoided or at least reduced. In addition, torque surges can be dampened and / or canceled by the elastic coupling 56 within the coupling unit 46 without the need to make adjustments to the gearbox 18.

[0052] In the embodiment of the coupling unit 46 shown in Fig. 6, in comparison to the embodiments of the coupling unit 46 shown in Figs. 3 to 4, the planetary carrier hub 30 is mounted indirectly in the coupling unit 46 by means of the bearing 48. In the axial direction between the rotor shaft 16 and the planetary carrier hub 30, a transition piece 58 is provided, which is fastened to the rotor shaft 16 and the planetary carrier hub 30 at the end face by means of rotor fastening means 60. The transition piece 58 can form a bearing surface 64 for the bearing 48 on a larger bearing diameter than the planetary carrier hub 30. In the illustrated embodiment, the bearing 48 is designed in the manner of a torque bearing, in particular a four-point bearing, as a double-row tapered roller bearing in an X arrangement.The coupling housing 50 of the coupling unit 46 is fastened to the gearbox 18, in particular to the ring gear 42 and / or to the gearbox housing 26, via gearbox fastening means 66, wherein the gearbox fastening means 66 are easily accessible from radially outside the coupling unit 46. The coupling unit 46 can already be pre-assembled to the rotor shaft 16 and / or to the rotor bearing housing 52 when the rotor-side planetary carrier hub 30 of the gearbox 18 is inserted into the coupling unit 46. Finally, the coupling unit 46 can be releasably fastened to the gearbox 18 using the gearbox fastening means 66 in order to fix the desired relative position achieved.

[0053] In the embodiment of the coupling unit 46 shown only in principle in Fig. 7, the torque arm 54 is supported on the rotor bearing housing 52 via a support foot 68. The support foot 68 can be fastened to the rotor bearing housing 52 in a rotationally fixed manner, for example by screwing. Additionally or alternatively, the coupling unit 46 can have an axial support 70 with axial spring elements 72 and / or axial damper elements, with the aid of which a tilting moment caused by a dead weight 74 of the gearbox 18 can be supported on the rotor bearing housing 52 via the same or another support foot 68. Depending on the design of the axial spring elements 72 and / or axial damper elements, vibrations introduced by the rotor shaft 16 can be dampened and / or canceled out in the axial support 70. The rotor bearing housing 52 is attached to a machine support 76, which can form a foundation for the gearbox 18.The at least one support foot 68 can additionally or alternatively be supported on the machine carrier 76, in particular be fixed in a movement-proof manner.

[0054] In the embodiment of the drive train 14 shown in Fig. 8, in comparison to the embodiment of the drive train 14 shown in Fig. 7, the rotor shaft 16 is mounted spherically in the rotor bearing housing 52, for example, as part of a three-point bearing of the rotor shaft 16. The bearing 60 of the coupling unit 48 can not only assume the function of supporting the planetary carrier hub 30, but can also additionally assume the function of forming an abutment for the bearing of the rotor shaft 16 in the rotor bearing housing 52, which abutment can in particular support a tilting moment introduced by the rotor shaft 16. In particular, the bearing 60 is designed as two angular contact ball bearings in an X arrangement, whereby any tilting moments that occur can be effectively supported on the coupling housing 50.The coupling housing 50, in turn, can be supported on a foundation, in particular the machine support 68, via a support foot 68, wherein a spring and / or damper element 78 can preferably be provided between the support foot 68 and the foundation and / or machine support 68. In addition, it can be provided that the dead weight of the transmission 18 and / or the generator 20 can also be supported via the same support foot 68.Thus, the bearing 48 of the coupling unit 46 can also assume the function of supporting a tilting moment introduced by the dead weight of the gearbox 18 and / or the generator 20, wherein the tilting moment introduced into the coupling unit 46 on the input side by the rotor shaft 16 and the tilting moment introduced into the coupling unit 46 on the output side via the planetary carrier hub 30 are preferably compensated in the static state and / or in the dynamic state at least partially, in particular almost completely, preferably by 90% to 100%, in the region of the bearing 48.

Claims

Patent claims Drive train (14) for a wind turbine (10), with a gearbox (18) for transmitting and converting a torque originating from a rotor shaft (16) of a rotor (12) mounted in a rotor bearing arrangement, wherein the gearbox (18) has an input gearbox component, in particular a planetary carrier (32), which is unsupported at least on the rotor side, for introducing the torque into the gearbox (18), wherein the input gearbox component partially protrudes on the rotor side from a gearbox housing (26) and / or a ring gear (42) of the gearbox (18), and a coupling unit (46) designed separately from the rotor shaft (16), the rotor bearing arrangement and the gearbox (18) for allowing a torque-transmitting and torsionally rigid, in particular form-fitting, coupling of the rotor shaft (16) to the input gearbox component within the coupling unit (46),wherein the coupling unit (46) has a bearing (48) for supporting the unsupported input transmission component within the coupling unit (46), wherein the input transmission component is supported on the rotor side exclusively by the bearing (48) within the coupling unit (46). Drive train (14) according to claim 1, wherein the transmission (18) has at least one planetary stage (28) with a planetary gear, and the input transmission component is a planet carrier (32) of the planetary gear pointing towards the rotor shaft (16), wherein the planet carrier (32) has an unsupported planet carrier hub (30) projecting towards the rotor shaft (16), wherein the planet carrier hub (30) is supported in the coupling unit (46). Drive train (14) according to claim 1 or 2, wherein the bearing (48) bears directly against the input transmission component or the coupling unit (46) has a Input transmission component has a transition piece (58) fixedly connected to it for providing a bearing surface (64) on a bearing diameter different from the input transmission component, wherein the bearing (48) bears directly against the bearing surface (64) of the transition piece (58).

4. Drive train (14) according to one of claims 1 to 3, wherein the bearing (48) is designed as a plain bearing or rolling bearing, in particular a tapered roller bearing.

5. Drive train (14) according to one of claims 1 to 4, wherein the coupling unit (46) has at least one support foot (68) for transferring mechanical loads to a stationary component, in particular a rotor bearing housing (52) of the rotor bearing arrangement provided for supporting the rotor shaft (16) and / or for transferring mechanical loads to the transmission housing (26) and / or ring gear (42) of the transmission (18) and / or for transferring mechanical loads to a foundation for supporting the drive train (14).

6. Drive train (14) according to one of claims 1 to 5, wherein the coupling unit (46) has a torque support (54) for supporting the torque coming from the rotor shaft (16) on a / the stationary component, in particular a rotor bearing housing (52) of the rotor bearing arrangement provided for supporting the rotor shaft (16) and / or for transferring mechanical loads to the gear housing (26) and / or ring gear (42) of the gear (18) and / or for transferring mechanical loads to a foundation for supporting the drive train (14).

7. Drive train (14) according to one of claims 1 to 6, wherein the coupling unit (46) has an axial spring element (72) and / or an axial damper element for the flexible support of axial forces caused in particular by the dead weight (74) of the transmission (18). Drive train (14) according to one of claims 1 to 7, wherein the coupling unit (46) has an elastic coupling (56) connectable to the rotor shaft (16), wherein the elastic coupling (56) is designed to be torsionally rigid and flexible in the axial direction and / or in the radial direction. Drive train (14) according to one of claims 1 to 8, wherein the coupling unit (46) has a, in particular central, through-opening for passing a pitch tube between the rotor shaft (16) and the transmission (18). Drive train (14) according to one of claims 1 to 9, wherein the coupling unit (46) has a lubricant channel for exchanging a lubricant, in particular lubricating oil, between the rotor shaft (16) and the input transmission component.Drive train (14) according to one of claims 1 to 10, wherein the coupling unit (46) has at least one rotor fastening means (60) accessible from radially outside the coupling unit (46) for releasably fastening the coupling unit (46) to the rotor shaft (16) and / or at least one transmission fastening means (66) accessible from radially outside the coupling unit (46) for releasably fastening the coupling unit (46) to the input transmission component of the transmission (18).A series of drive trains (14), comprising a first drive train designed for a first requirement profile according to one of claims 1 to 11 and a second drive train designed for a second requirement profile according to one of claims 1 to 11, wherein the transmission (18) of the first drive train and the transmission (18) of the second drive train are designed substantially identically and the coupling unit (46) of the first drive train is designed differently from the coupling unit (46) of the second drive train. A series according to claim 12, wherein the first drive train is connected to a first generator and the second drive train is connected to a second generator, wherein the first generator and the second generator are designed for different power profiles. A series of drive trains (14), with a first generator designed for a first power profile and a first drive train connected to the first generator according to one of claims 1 to 11, as well as a second generator designed for a second power profile and a second drive train connected to the second generator according to one of claims 1 to 11, wherein the transmission (18) of the first drive train and the transmission (18) of the second drive train are designed essentially identically and the coupling unit (46) of the first drive train is designed differently from the coupling unit (46) of the second drive train.Data agglomerate with data packets combined in a common file or distributed across different files for mapping the three-dimensional shape and / or the interactions of all components provided in the drive train (14) according to one of claims 1 to 11, wherein the data packets are prepared to carry out an additive manufacture of the components of the drive train, in particular by 3D printing, when processed by a data processing device for operating a machine tool for the additive manufacture of devices and / or to carry out a simulation of the functioning of the drive train when processed by a data processing device for carrying out a technical simulation and to output simulation results generated in this way for further use, in particular for the purpose of. Proof of fatigue strength depending on changing loads and / or changing temperature loads.

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